JP6391513B2 - Foam molded body for vehicle seat, headrest for vehicle seat, and armrest for vehicle seat - Google Patents

Description

  The present invention relates to a foamed body for a vehicle seat such as a headrest for a vehicle seat, an armrest for a vehicle seat, and the like.

  The above-mentioned foamed molded article for a vehicle seat is an apparatus for a vehicle seat in which a foamed resin that has been foamed into a predetermined shape is covered with a skin. This foaming molding is a headrest, an armrest, etc., for example. The headrest is a vehicle device that receives the head of a seated person seated on the vehicle seat. The armrest is a vehicle device that receives the arm of a seated person seated on the vehicle seat.

(Patent Document 1)
Conventionally, according to Patent Document 1, a foam molded body such as a headrest is known. In this foamed molded product, a skin containing a stay (ie, a support) is placed in a mold, and a foamed resin raw material is injected into this skin, and the foamed resin raw material is contained in a state where the stay is built (ie, inserted). The foamed molded body is formed by foaming and curing.

  In this conventional foamed molded article, an opening for injecting the foamed resin material is formed by a pair of tongue pieces (that is, an overhanging portion), and the foamed resin material is injected into the skin through the opening. The boundary part between the main body part of the epidermis and the tongue piece protruding from the main body part was a right-angled shape.

(Patent Document 2)
Conventionally, Patent Document 2 discloses a headrest having a structure in which a hole for stay is provided on a line of a slit opening for injecting a foaming raw material. The skin used in the headrest has a main body part that covers the foamed resin that has been foamed into a predetermined shape, and a two-layer overlapping part that is an overhanging part that projects from the main body part. The boundary part between the main body part of the epidermis and the overhang part of the epidermis was sewn at a right angle.

(Patent Document 3)
Conventionally, Patent Reference 3 discloses a headrest using a foamable resin. In this headrest, an opening is formed by a pair of folding projections, and the foamed resin raw material is injected into the outer skin through this opening to form the headrest. Also in this headrest, the boundary part between the protruding part of the epidermis and the main body part of the epidermis was a right-angled shape.

(Patent Document 4)
Conventionally, Patent Reference 4 discloses a headrest using a foamable resin. In this headrest, an annular band having an opening projects from the main body of the skin. A foamed resin material is injected into the skin through the opening of the annular band. Also in this headrest, the boundary portion between the overhang portion of the epidermis and the main body portion of the epidermis was a right-angle shape.

  As described above, in the conventional foamed molded article, the skin 101 is formed by the main body 102 and the overhang 103 as shown in FIGS. The skin 101 in FIG. 14A is in a state where the back surface appears on the front side. 14A, the skin 101 is turned upside down through the opening 106 of the overhanging portion 103 and the overhanging portion 103 is folded into the main body 102, whereby the surface of the skin 101 appears on the front side.

  As shown in FIG. 14D, the sewing operation for the skin 101 is performed by passing the needle 105 through the skin 101 while pressing the skin 101 with the pressing member 104. In FIG. 14A, the stitching operation up to the boundary portion A is performed by advancing the needle 105 (see FIG. 14D) as indicated by an arrow B.

  As described above, in the conventional foamed molded article, as shown in FIGS. 14A and 14C, the boundary portion A between the main body portion 102 of the skin 101 and the overhang portion 103 of the skin 101 is a right-angled shape. Was stitched together. That is, it was sewn at right angles. In this right-angle stitching, stitching is performed as shown by an arrow B in FIG. 14A, and then a needle 105 (see FIG. 14D) at a boundary portion A as shown by an arrow C in FIG. 14B. This is done by turning the epidermis 101 while changing the sewing direction and changing the sewing direction to a right angle as shown by the arrow D.

  When such right-angle sewing is performed, the needle hole is greatly expanded as indicated by symbol E in FIG. When the needle hole is greatly expanded in this way, when the foamed resin raw material is injected into the inside of the skin 101 through the opening 106 in FIG. 14A or any other position and the raw material is further foamed, The foamed resin raw material sometimes oozes out.

  When such exudation occurs, when the foaming and curing of the foaming material is finished and the headrest 107 in FIG. 15A is completed, as shown in FIGS. 15A and 15B, the skin 101 Extrusion F of the foamed resin material occurs at the boundary portion A between the main body portion 102 and the overhang portion 103 of the skin 101 (that is, where the needle hole is enlarged by right-angle stitching), and the appearance of the headrest 107 is greatly impaired. There is a risk of being.

Japanese Patent Laid-Open No. 7-031759 JP 2000-153084 A JP-A-2005-323761 JP 2007-050621 A

  The present invention has been made in view of the above-mentioned problems in the conventional apparatus, and in the foamed molded article having an overhang portion on a part of the skin, the foam raw material resin is formed at the boundary portion between the overhang portion and the main body portion. The first object is to prevent the skin from oozing out.

  In addition, a second object of the present invention is to ensure that the work for achieving the above object can be performed without failure.

The foamed molded product for vehicle seats according to the present invention is a foamed molded product for vehicle seats having a foamed resin that has been foamed into a predetermined shape, and a skin covering the resin after foaming. And a main body part covering the resin after foaming and a projecting part projecting from the main body part, and the main body part and the projecting part are formed by stitching skin materials facing each other or adjacent to each other. The boundary portion between the main body portion and the overhang portion is stitched in a curved shape, and a connecting portion for connecting the facing skin materials is provided in the vicinity of the outside of the curved-shaped sewing line. The connecting portion is formed by a sewing line that is continuous with the curved sewing line .

  According to the present invention, since the boundary portion between the overhang portion and the main body portion is sewn in a curved shape, it is possible to prevent a large needle hole from being generated in the boundary portion. For this reason, exudation of urethane resin does not occur at the boundary portion, and the appearance of the foamed molded body such as a headrest can be maintained clean.

  Furthermore, in the present invention, since a curved stitch line is provided at the boundary portion between the body portion and the overhang portion of the skin, when any member is inserted into the boundary portion, the member inserted due to the presence of the curved shape May escape. However, in the present invention, since the connecting portion for connecting the skin material is provided near the outside of the curved sewing line, when the insertion member is inserted into the boundary portion, the side edge of the insertion member is firmly received by the connecting portion. It is done. For this reason, even if the curve-shaped sewing line exists, it can prevent reliably that an insertion member slips out from a boundary part. As a result, according to the present invention, it has become possible to reliably perform the function of preventing the urethane raw material resin from exuding from the skin using the curved sewing line.

Oite for a vehicle seat foam molded body according to the present invention, the connecting portion is formed by a stitch line that is continuous with sewing line of the curved shape. With this configuration, the curved sewing line and the connecting portion can be formed by one sewing process, so that workability is good.

  In another aspect of the foam molded body for vehicle seats according to the present invention, the connecting portion is formed by a linear sewing line that is continuous with the curved sewing line. According to this aspect of the invention, the curved sewing line and the connecting portion can be formed by a single sewing process, so that workability is good.

  In still another aspect of the foam molded body for a vehicle seat according to the present invention, the connecting portion is formed by a right-angled sewing line that is continuous with the curved sewing line. According to this aspect of the invention, the curved sewing line and the connecting portion can be formed by a single sewing process, so that workability is good.

  In still another aspect of the foam molded article for vehicle seats according to the present invention, the connecting portion is provided at a position in contact with a member inserted into the opening of the overhang portion. According to this aspect of the invention, the inserted member can be accurately received by the connecting portion, and the inserted member can be reliably prevented from coming out of the overhang portion.

  In still another aspect of the foam molded body for vehicle seats according to the present invention, the skin is formed of a single layer of flexible material. The skin material generally has a case of a single layer and a case of a multilayer. The one-layer skin material is formed of, for example, a fabric such as a woven fabric or a knitted fabric, leather, synthetic leather, or the like (hereinafter referred to as “one-layer material”). The two-layer material is, for example, a material obtained by stacking wadding (that is, padding, padding, etc.) on the one-layer material. The wadding is, for example, a urethane foam material having a thickness of 3 to 5 mm. The three-layer material is, for example, a material obtained by laminating a wadding on the one-layer material described above and further laminating a film thereon. The film is, for example, a polyurethane film or a polyethylene film. The thickness of the film is, for example, 30 to 50 μm. In the present invention, the skin can be formed from the above-mentioned one-layer material.

  When the skin is formed of a single layer material, the skin is soft and has low rigidity. Therefore, in this case, it is difficult for the epidermis to maintain its own shape. In the case of foamed molded products for vehicle seats such as headrests and armrests, an opening is often formed at the boundary between the body part and the overhang part of the skin, and foaming and curing is performed by injecting foamed resin into the skin. When the opening is deformed, the foamed resin may leak from the opening. When the skin is a single layer, the skin is easily deformed, so the opening is also easily deformed. In order to prevent deformation of the opening, it is desirable to insert an opening shaping jig into the opening and apply tension to the opening. Such tensioning is particularly necessary in the case of a single-layer skin.

  However, when a curved sewing line is provided in the boundary portion as in the present invention, the opening shaping jig inserted into the opening in the boundary portion moves along the curved sewing line and comes out of the opening. There is a fear. However, if the connecting portion is provided in the vicinity of the outside of the curved sewing line according to the present invention, the opening shaping jig can be supported by the connecting portion, so that the opening shaping jig can be effectively prevented from coming off.

  Next, the headrest for a vehicle seat according to the present invention has a post-foaming resin that has been foamed into a predetermined shape, and a skin covering the post-foaming resin, and receives the head of the seated person In the vehicle seat headrest, the skin includes a main body portion covering the resin after foaming and an overhang portion protruding from the main body portion, and the main body portion and the overhang portion face each other. Alternatively, it is formed by sewing adjacent skin materials, and a boundary portion between the main body portion and the overhanging portion is stitched by a curved sewing line, and in the vicinity of the outside of the curved sewing line, It is characterized by the connection part which connects the facing skin material facing. According to this headrest, the same effect as that of the foamed molded body for vehicle seats according to the present invention can be obtained.

  Next, the vehicle seat armrest according to the present invention includes a foamed resin that has been foamed into a predetermined shape, and a skin that covers the resin after foaming, and receives a seated person's arm. In the seat armrest, the skin has a main body portion covering the resin after foaming and an overhang portion protruding from the main body portion, and the main body portion and the overhang portion face each other. It is formed by stitching adjacent skin materials, and the boundary portion between the main body portion and the overhanging portion is stitched together by a curved stitch line, and is opposed to each other in the vicinity of the outside of the curved stitch line. The connection part which connects the skin material to perform is provided. According to this armrest, it is possible to obtain the same effect as the foam molded body for a vehicle seat according to the present invention.

  According to the foam molded body for a vehicle seat, the headrest for a vehicle seat, and the armrest for a vehicle seat according to the present invention, since the boundary portion between the overhang portion and the main body portion is sewn in a curved shape, a large needle hole is formed in the boundary portion. It can be prevented from occurring. For this reason, exudation of urethane resin does not occur at the boundary portion, and the appearance of the foamed molded body such as a headrest can be maintained clean.

  Furthermore, in the present invention, since a curved stitch line is provided at the boundary portion between the body portion and the overhang portion of the skin, when any member is inserted into the boundary portion, the member inserted due to the presence of the curved shape May escape. However, in the present invention, since the connecting portion for connecting the skin material is provided near the outside of the curved sewing line, when the insertion member is inserted into the boundary portion, the side edge of the insertion member is firmly received by the connecting portion. It is done. For this reason, even if the curve-shaped sewing line exists, it can prevent reliably that an insertion member slips out from a boundary part. As a result, according to the present invention, it has become possible to reliably perform the function of preventing the urethane raw material resin from exuding from the skin using the curved sewing line.

It is a perspective view showing one embodiment of a headrest for a vehicle seat which is one embodiment of a foamed molded product for a vehicle seat according to the present invention. It is process drawing which shows an example of the manufacturing method of the headrest of FIG. It is a top view which shows the state before sewing of the skin used with the headrest of FIG. It is a perspective view which shows the state in which the skin for the headrest of FIG. 1 formed by stitching together the skin material shown in FIG. 3 was turned over. It is a perspective view which shows the state which turned over the skin of FIG. (A) schematically shows a curve-shaped sewing process used in the present invention, and (b) schematically shows a comparative example of the sewing process. It is a perspective view which shows the skin assembly set to the state with which it mounts | wears with the cavity of a foaming mold. It is a perspective view which shows one process of a foam molding process. (A) is a figure which shows typically one Embodiment of the curve-shaped sewing process used by this invention, (b) is an enlarged view of the principal part of (a), (c) is the sewing process. It is a perspective view which shows an example of a result. It is a figure which shows the skin raw material which is the principal part of other embodiment of the headrest for vehicle seats which is one Embodiment of the foaming molding for vehicle seats which concerns on this invention. It is a perspective view which shows the state in which the skin for the headrest of FIG. 1 formed by stitching together the skin material shown in FIG. It is a perspective view which shows the state which turned over the skin of FIG. It is a perspective view which shows one Embodiment of the armrest for vehicle seats which is other embodiment of the foaming molding for vehicle seats which concerns on this invention. It is a figure which shows typically one process for manufacturing the conventional foaming molding for vehicle seats. (A) is a perspective view which shows an example of the headrest which is an example of the conventional foaming molding for vehicle seats, (b) is a figure which expands and shows the principal part of the headrest.

(First embodiment of a headrest which is an example of a foam molded article)
Hereinafter, a foamed molded body for a vehicle seat according to the present invention will be described based on an embodiment with a headrest as an example. Of course, the present invention is not limited to this embodiment. In addition, in the drawings attached to the present specification, components may be shown in different ratios from actual ones in order to show characteristic parts in an easy-to-understand manner.

(Overall shape of headrest)
FIG. 1 shows a vehicle seat headrest which is an embodiment of a foamed molded product for a vehicle seat according to the present invention. The headrest 1 includes a U-shaped or U-shaped metal frame 2, a pad 3 as a resin after foaming provided around the frame 2, and a skin 4 covering the entire pad 3. Have.

  The frame 2 has column parts 2a and 2b that are exposed to the outside of the skin 4, and a connecting part 2c that connects the column part 2a and the column part 2b. The pad 3 is a resin in which urethane, which is a foamable resin, is foamed and cured to have a predetermined shape. The skin 4 has a front skin material 4a, a right side skin material 4b on the right side for the seated person, and a left side skin material 4c on the left side for the seated person.

(Headrest manufacturing process)
The headrest 1 in FIG. 1 is manufactured, for example, by a manufacturing method shown as a process chart in FIG. This manufacturing method includes a skin creation step P1, a pretreatment step (ie, a skin assembly creation step) P2, a skin assembly setting step P3, a urethane injection step P4, and a product removal step P5. And have.

(Skin making process)
The skin creation step P1 is a step of creating the skin 4 of FIG. Specifically, as shown in FIG. 3, first, a front skin material 4a, a right side skin material 4b, and a left side skin material 4c having a predetermined shape are cut out from one skin material. The frame insertion hole 7 and the injection nozzle insertion hole 14 which are holes for inserting the frame 2 in FIG. 1 are also cut out.

  The skin material generally has a case of a single layer and a case of a multilayer. The one-layer skin material is formed of, for example, a fabric such as a woven fabric or a knitted fabric, leather, synthetic leather, or the like (hereinafter referred to as “one-layer material”). The two-layer material is, for example, a material obtained by stacking wadding (that is, padding, padding, etc.) on the one-layer material. When covering the pad 3, the padding contacts the pad 3. The wadding is, for example, a urethane foam material having a thickness of 3 to 5 mm. The three-layer material is, for example, a material obtained by laminating a wadding on the one-layer material described above and further laminating a film thereon. When covering the pad 3, the film contacts the pad 3. The film is, for example, a polyurethane film or a polyethylene film. The thickness of the film is, for example, 30 to 50 μm. In the case of this embodiment, each skin material 4a, 4b, 4c is formed with said 1 layer raw material.

  In FIG. 3, after the front skin material 4a is bent around the line X0, the front skin material 4a, the right side skin material 4b, and the left side skin material 4c are sewn along the alternate long and short dash line G1, and further the front skin material 4a. By stitching the protruding pieces 4d1 and the protruding pieces 4d2 along the alternate long and short dash line G2, a skin 4 (inverted state) as shown in FIG. 4 is formed. The state shown in FIG. 4 is a state in which the back surface of the skin 4 appears on the front side, and the sewing line G1 and the sewing line G2 appear on the front side. A portion where the projecting piece 4d1 and the projecting piece 4d2 are sewn together by a sewing line G2 forms an overhanging portion 9 projecting from the main body portion 8 of the skin 4. In the overhang portion 9, the tip side L between one sewing line G2 and the other sewing line G2 is not stitched, and is a tip opening. Further, the root side K between one sewing line G2 and the other sewing line G2 is not sewn, and is a root opening.

  The boundary portion A between the sewing line G1 and the sewing line G2, that is, the boundary portion A between the main body portion 8 and the overhang portion 9, is sewn into a curved shape. That is, a curved sewing line G3 is formed between the sewing line G1 and the sewing line G2. The curved portion of the sewing line G3 is sewn into a shape of a part of a circle as shown in FIG. More specifically, the boundary portion A is sewn into a shape of approximately ¼ of a circle (a circle corresponding to an angle of 90 °). The radius of this circle is set to 10 mm or more.

When the overhang portion 9 is formed by performing the sewing process along the sewing line G2 and the sewing line G3, the following sewing process is performed.
(1) Start sewing from point a in FIG. Point a is a point on or near the end edges of the projecting pieces 4d1, 4d2.
(2) Perform straight stitching J1 up to point b. The point b is a point between the position H where the curved sewing line G3 starts and the root opening K of the overhang portion 9.
(3) Straight stitch J2 is performed from point b to point c. Point c is the starting point of the sewing line G2 for sewing the overhang portion 9 together.
(4) Perform sewing according to the sewing line G2 from the point c. The sewing line G2 is a substantially linear sewing line.
(5) At the boundary portion A between the main body portion 8 and the overhang portion 9, the curved stitch G3 is performed up to the point d following the sewing line G2. Point d is a point on or near the edge of the front skin material 4a.
(6) Although the points a and c are drawn as separate points in FIG. 4, the points a and c may be the same point.

  As described above, as shown in FIG. 4B, the connecting portion 20 is formed by the straight stitches J1 and the tip portions of the straight stitches J2 near the outside of the curved stitch line G3. The connecting portion 20 is a portion where a pair of protruding pieces 4d1 and 4d2 forming the overhanging portion 9 are connected by stitching.

  FIG. 5 shows a state in which the skin 4 is turned upside down through the root opening K and the tip opening L of the overhang portion 9 in FIG. That is, the state shown in FIG. 5 is a state in which the surface of the skin 4 appears on the front side, and the sewing line G1 and the sewing line G2 are hidden on the back side. In FIG. 4, the overhang portion 9 formed by the projecting pieces 4 d 1 and 4 d 2 projects outside the main body portion 8 of the skin 4, but the overhang portion 9 projects over the inside of the main body portion 8 of the skin 4 in FIG. 5. .

  In the current sewing machine, when the seam has a circular shape with a radius of 10 mm or more, as shown in FIG. 6 (a), the sewing needle 5 is sewn while moving smoothly along the circular shape. Work can be done. On the other hand, when the radius of the seam is less than 10 mm, it is difficult to perform the sewing operation while continuously moving the sewing needle as shown in FIG. It is necessary to change the sewing direction N of the needle by rotating the sewing product while dropping the needle 5 each time the needle 5 is moved. In this case, the needle hole was inevitably enlarged when the sewing product was rotated. However, in this embodiment, since the radius of the curved shape of the seam of the boundary portion A in FIGS. 3 and 4 is set to 10 mm or more, a large needle hole is not formed in the boundary portion A.

  In a general sewing operation, the sewing process is performed by moving the needle along the outer edge line using the outer edge line of the sewing as a mark. Therefore, when the seam of the boundary portion A is circular as described above, it is desirable to cut the outer edge line of the skin 4 corresponding to the boundary portion A into a circular shape having a radius of 10 mm or more in advance. For this reason, in this embodiment, a circular shape having a radius of 10 mm or more is formed in a corresponding portion of a pattern used when cutting out the front skin material 4a of FIG. 3 from one material, and the front skin material is based on this pattern. The boundary part A of 4a is cut out.

(Preprocessing)
In the pretreatment step P2 of FIG. 2, the support 2a or the support 2b of the frame 2 of FIG. 1 is inserted into one of the frame insertion holes 7 of the skin 4 of FIG. 5, and further, as shown in FIG. Is inserted into the inside of the skin 4, and then the column part 2 a or 2 b is extracted from the other side of the frame insertion hole 7, the two column parts 2 a and 2 b are outside the skin 4, and the connecting part 2 c is Keep it inside. Thereafter, an opening shaping jig 10 (see FIG. 5) having a length slightly longer than the root opening K of the overhang portion 9 and having a thin plate thickness that can be inserted into the opening K is inserted into the opening K in FIG. . Next, the tip of the injection nozzle 12 is inserted into the skin 4. Thereby, the skin assembly 13 is created.

(Set process to mold)
Next, in the setting process P3 to the mold shown in FIG. 2, the skin assembly 13 is set in the cavity of the foaming mold 16 as shown in FIG. Next, as shown in FIG. 8B, the foaming mold 16 is closed. The cavity has a concave shape that matches the shape of the desired headrest.

(Urethane injection process)
Next, in the urethane injection step P4 in FIG. 2, as shown in FIG. 8B, the head portion 17 of the urethane injector is pressed against the mold, and urethane is injected into the mold. Furthermore, after the urethane injection is completed, the mixture is held at room temperature for a certain period of time. Thereby, urethane foams and hardens within the outer skin 4, and a urethane foam conforming to the shape of the cavity of the mold is formed. The shape of this urethane foam is the desired headrest shape.

(Product removal process)
Next, in the product take-out process P5 in FIG. 2, the mold 16 in FIG. 8B is opened, the skin assembly 13 containing the urethane resin after foaming is taken out, and the injection nozzle 12 and the opening shaping jig 10 are further installed. By extracting, a finished product of the headrest 1 as shown in FIG. 1 is obtained as a foamed molded body. In the headrest 1, the main body 8 of the skin 4 covers the urethane foam pad 3 that is a resin after foaming. The overhanging portion 9 of the epidermis 4 protrudes toward the inside of the main body portion 8. The overhanging portion 9 is formed by stitching together the two projecting pieces 4d1 and 4d2 of the front skin material 4a shown in FIG. 3 along a sewing line G2. The overhanging portion 9 has a root opening K and a tip opening L. In the process of foaming the pad 3, the overhanging portion 9 in the main body 8 is pressed from above and below by the foaming pad 3, thereby The opening K and the tip opening L are automatically closed. For this reason, the urethane resin does not leak from the root opening K and the tip opening L.

  In the headrest of the present embodiment described above, as shown in FIG. 4, the boundary portion A between the main body portion 8 of the skin 4 and the overhanging portion 9 of the skin 4 is sewn into a circular shape, that is, a curved shape. If this is shown in an easy-to-understand manner, it is as shown in FIG. More specifically, the boundary portion A is sewn into a circular shape having a radius of 10 mm or more. If the radius of the seam is set to less than 10 mm, the stitching process changes the direction of travel by rotating the sewing item with the needle dropped at every short interval e as shown in FIG. 6 (b). Had to do while. If it carries out like this, when rotating a sewing thing centering on a needle | hook, there exists a possibility that a large needle hole may be formed in a sewing thing.

  In this way, the skin assembly 13 is formed as shown in FIG. 7 on the basis of the skin 4 having a large needle hole at the boundary portion A between the main body portion 8 and the overhanging portion 9 of the skin 4, and based on this skin assembly 13. When the headrest 1 shown in FIG. 1 is created, urethane oozes out of a large needle hole during the urethane injection and molding process shown in FIG. 8B. As a result, the headrest 1 shown in FIG. 15A and FIG. As shown, the appearance of the headrest 1 may be impaired.

  On the other hand, if the boundary portion A is sewn in a continuous circular shape, that is, a curved shape (G3) as in this embodiment shown in FIGS. The generation of a large needle hole can be prevented, and as shown in FIG. 9C, the urethane resin does not ooze out at the boundary portion A between the overhang portion 9 and the main body portion 8, and the appearance of the headrest is improved. It can be kept clean.

  In the present embodiment, the insertion piece 10 a of the opening shaping jig 10 of FIG. 5 is inserted into the root opening K of the overhang portion 9. This is because the urethane raw material resin is injected into the inside of the skin 4 in the urethane injection step shown in FIG. 8B, foams, and further hardens, the shape of the opening K is deformed and the urethane raw material leaks out. This is done to prevent this.

  In the present embodiment, as shown in FIG. 4, since the curved seam G3 is provided at the boundary portion A between the main body portion 8 and the overhang portion 9 of the skin 4, the seepage of urethane resin from the boundary portion A Could be prevented. However, when such a curved sewing line G3 is provided, when the opening adjusting jig 10 is inserted into the opening K of the skin 4, as shown by an arrow M in FIG. As a result, there arises a problem that the opening adjusting jig 10 comes out, that is, it is difficult to firmly attach the opening adjusting jig 10 to the opening K.

  On the other hand, in the present embodiment, as shown in FIG. 4, since the connecting portion 20 is provided in the vicinity of the outside of the curved sewing line G3, the opening adjusting jig 10 is attached as indicated by the symbol M in FIG. When inserted into the opening K of the skin 4, the side edge of the insertion piece 10a of the opening adjusting jig 10 is firmly received by the connecting portion 20 as shown in FIG. Even if it does, it can prevent reliably that the opening adjustment jig | tool 10 slips out of the opening K. For this reason, according to the present embodiment, the function of preventing the urethane raw material resin from exuding from the skin 4 using the curved sewing line G3 can be reliably performed without failure.

(Second embodiment of a headrest which is an example of a foam molded article)
10, FIG. 11 and FIG. 12 show the main part of a second embodiment of a headrest which is an example of a foamed molded product according to the present invention. 10, FIG. 11 and FIG. 12 correspond to FIG. 3, FIG. 4 and FIG. 5 in the first embodiment, respectively. In the present embodiment, a modification is added to the connecting portion 20 in the first embodiment shown in FIG.

In this embodiment, when the overhang portion 9 is formed by performing the sewing process along the sewing line G2 and the sewing line G3 in FIG. 11, the following sewing process is performed.
(1) Sewing is started from point a in FIG. Point a is a point on or near the end edges of the projecting pieces 4d1, 4d2.
(2) Perform right angle stitching J3 through point b to point c. Right-angle sewing means to include a case where the sewing direction is changed at a strictly right angle (angle 90 °) and a case where the angle is changed almost at an angle. The point b is a point between a position H where the curved sewing line G3 starts and a root opening K of the overhang portion 9. The point c is a point on or near the edge of the front skin material 4a.
(3) Next, sewing is performed from the point c according to the sewing line G3. The sewing line G3 has a curved shape at the boundary portion A between the main body portion 8 and the overhang portion 9.
(4) The sewing is performed in accordance with the linear sewing line G2 up to the point d following the sewing line G3. The point d is a point on or near the end edges of the projecting pieces 4d1 and 4d2. The point d may be the same point as the point a.

  As described above, as shown in FIG. 11B, in the vicinity of the outside of the curved sewing line G3, the connecting portion 20 is formed by the portion from the position H to the point b of the right-angle sewing J3. The connecting portion 20 is a portion that connects the pair of projecting pieces 4d1 and 4d2 forming the overhang portion 9 by stitching.

  FIG. 12 shows a state in which the skin 4 is turned upside down through the root opening K and the tip opening L of the overhang portion 9 in FIG. That is, the state shown in FIG. 12 is a state in which the surface of the skin 4 appears on the front side. In FIG. 11, the overhanging portion 9 formed by the projecting pieces 4 d 1 and 4 d 2 overhangs outside the main body portion 8 of the skin 4, but in FIG. 12, the overhanging portion 9 overhangs inside the main body portion 8 of the skin 4. .

  Also in the headrest of the present embodiment, as shown in FIG. 11, the boundary portion A between the body portion 8 of the skin 4 and the overhang portion 9 of the skin 4 is sewn into a circular shape, that is, a curved shape. For this reason, it is possible to prevent a large needle hole from occurring in the boundary portion A, and as a result, no seepage of urethane resin occurs in the boundary portion A between the overhanging portion 9 and the main body portion 8, and the appearance of the headrest is improved. It can be kept clean.

  Further, in this embodiment, when a curved sewing line G3 is provided at the boundary portion A in order to prevent the urethane stock solution from seeping out, the opening adjusting jig 10 is opened to the opening of the skin 4 as shown by an arrow M in FIG. When inserted into K, there arises a problem that the opening adjusting jig 10 comes out along the curved shape of the sewing line G3, that is, it is difficult to firmly attach the opening adjusting jig 10 to the opening K. .

  On the other hand, in the present embodiment, as shown in FIG. 11B, the connecting portion 20 is provided in the vicinity of the outside of the curved stitch line G3. When the tool 10 is inserted into the opening K of the skin 4, the side edge of the insertion piece 10a of the opening adjusting jig 10 is firmly received by the connecting portion 20 as shown in FIG. For this reason, even if the curved sewing line G3 exists, it is possible to reliably prevent the opening adjusting jig 10 from coming out of the opening K. As a result, according to the present embodiment, the function of preventing the urethane raw material resin from exuding from the skin 4 using the curved sewing line G3 can be reliably performed without failure.

(Embodiment of an armrest which is another example of a foaming molding)
FIG. 13 shows an armrest which is another embodiment of the foamed molded product for vehicle seats according to the present invention. The armrest 51 has a pad 53 as a resin after foaming and a skin 54 covering the entire pad 53. Reference numeral 56 denotes a cup holder.

  The pad 53 is a resin formed into a predetermined shape by foaming and curing urethane, which is a foamable resin. The skin 54 includes a front skin material 54a, a right side skin material 54b, and a left side skin material 54c. The shaft member 55 protruding from the left and right side surface skin materials 54b, 54c is rotatably supported by a rotation support portion of a seat back (not shown) that receives the back of the seated person.

  The skin 54 has a main body portion 58 that covers the pad 53, an overhang portion 59 that protrudes into the main body portion 58, and an opening K that is formed at a boundary portion between the main body portion 58 and the overhang portion 59. ing. The urethane resin that is the raw material of the pad 53 is injected into the inside of the skin 54 through the opening K or any other part, and then foamed and cured to the desired shape shown in the figure.

  Also in the present embodiment, the boundary portion A between the main body portion 58 and the overhang portion 59 is stitched into a curved shape, for example, a circular shape to form a curved stitch line G3. This sewing operation is performed along a smooth sewing line continuously without changing the direction of the sewing needle. For this reason, there is no large needle hole in the boundary portion A. Since there is no large needle hole in the boundary portion A, it was possible to prevent the urethane from seeping out in the boundary portion A when the urethane resin was injected through the opening K and the urethane resin was further foamed. As a result, an armrest 51 having a beautiful appearance was obtained.

  Also in this embodiment, since the connecting portion 20 is provided in the vicinity of the outside of the curved sewing line G3, the opening adjusting jig 10 is inserted into the opening K of the skin 4 as indicated by the symbol M in FIG. In some cases, as shown in FIG. 5 (b), the side edge of the insertion piece 10a of the opening adjustment jig 10 is firmly received by the connecting portion 20, so that the opening adjustment jig is present even if the curved sewing line G3 exists. 10 can be reliably prevented from coming out of the opening K. For this reason, according to the present embodiment, the function of preventing the urethane raw material resin from exuding from the skin 4 using the curved sewing line G3 can be reliably performed without failure.

(Other embodiments)
The present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to the embodiments, and various modifications can be made within the scope of the invention described in the claims.

  For example, in 1st Embodiment regarding a headrest, as shown in FIG.5 (b), the connection part 20 was formed by the straight stitches J1 and J2. Moreover, in 2nd Embodiment regarding a headrest, as shown in FIG.12 (b), the connection part 20 was formed by the vicinity of the part which bent the right angle sewing J3 at right angle or substantially right angle. Since such a connecting part 20 may be in a state in which it can easily support the insertion piece 10a of the opening shaping jig 10 by connecting the protruding pieces 4d1 and 4d2 forming the overhanging part 9 of the skin 4, The connecting portion 20 can be formed by various methods without being limited to the straight stitch shown in FIG. 5 or the right angle stitch shown in FIG.

  For example, the connecting portion 20 can be formed by connecting the projecting pieces 4d1 and 4d2 using a short sewing line close to a dot shape. Moreover, the connection part 20 can also be formed by connecting the protrusions 4d1 and 4d2 with a metal needle using a closing device such as a stapler. Moreover, the connection part 20 can also be formed by connecting the protruding pieces 4d1 and 4d2 by bonding.

  1. 1. Headrest (foam molded body) Frames, 2a, 2b. Struts, 2c. 2. connecting part; 3. Pad (resin after foaming), Epidermis, 4a. Front skin material, 4b. Right side skin material, 4c. Left side skin material, 4d1, 4d2. 4. Projection piece 6. Sewing needle, 7. Frame insertion hole Body part, 9. 9. overhang, Opening shaping jig, 10a. Insert piece, 12. Injection nozzle, 13. Skin assembly, 14. 15. injection nozzle insertion hole; Foam mold, 17. 20. Head portion of urethane injection machine Connecting part, 51. Armrest, 53. Pad (resin after foaming), 54. Epidermis 54a. Front skin material, 54b. Right side skin material, 54c. Left side skin material, 55. Shaft member, 56. Cup holder, 58. Main body, 59. Overhang, A. Boundary part, a, b, c, d. A point on the sewing line, E. Needle hole, f. Exudation, G1. Main body sewing line, G2. Overhang part sewing line, G3. A curved stitch line; The position where the curved sewing line G3 begins, J1, J2. Straight stitch, J3. Right angle sewing Root opening, L. Tip opening; J. jig insertion direction; Sewing direction, X0. Bend line

Claims (7)

In a foam molded article for a vehicle seat having a foamed resin that has been foamed into a predetermined shape, and a skin covering the resin after foaming,
The skin has a main body part covering the resin after foaming, and an overhang part overhanging from the main body part,
The main body portion and the overhang portion are formed by stitching together facing or adjacent skin materials,
The boundary portion between the main body portion and the overhang portion is sewn into a curved shape,
In the vicinity of the outside of the curved stitch line, there is provided a connecting part that connects the skin materials facing each other ,
The vehicle seat foam molded body, wherein the connecting portion is formed by a stitch line continuous with the curved stitch line . The connecting portion is the curved shape linearly claim 1 vehicle seat foam molded article, wherein the is formed by stitching lines continuous in sewing lines. The connecting portion is the curved shape claim 1 vehicle seat foam molded article, wherein the is formed by stitching lines of right-angled continuous to the sewing line of the. The connecting portion is a vehicle seat foam molding according to any one of claims 1 to 3, characterized in that is provided at a position in contact with the member to be inserted into the opening of the flared portion body. The foamed article for a vehicle seat according to any one of claims 1 to 4 , wherein the skin is formed of one layer of a flexible material. In a vehicle seat headrest that has a foamed resin in a predetermined shape by foaming, and a skin covering the resin after foaming, and receives a head of a seated person,
The skin has a main body part covering the resin after foaming, and an overhang part overhanging from the main body part,
The main body portion and the overhang portion are formed by stitching together facing or adjacent skin materials,
The boundary portion between the main body portion and the overhang portion is stitched together by a curved sewing line,
In the vicinity of the outside of the curved stitch line, there is provided a connecting part that connects the skin materials facing each other ,
The vehicle seat headrest, wherein the connecting portion is formed by a sewing line that is continuous with the curved sewing line . In a vehicle seat armrest that has a foamed resin in a predetermined shape by foaming, and a skin covering the resin after foaming, and receives a seated person's arm,
The skin has a main body part covering the resin after foaming, and an overhang part overhanging from the main body part,
The main body portion and the overhang portion are formed by stitching together facing or adjacent skin materials,
The boundary portion between the main body portion and the overhang portion is stitched together by a curved sewing line,
In the vicinity of the outside of the curved stitch line, there is provided a connecting part that connects the skin materials facing each other ,
The vehicle seat armrest, wherein the connecting portion is formed by a sewing line continuous with the curved sewing line .

Images